Paint Brush and Manufacturing Method

ABSTRACT

A paint brush and method include a ferrule extending around and in contact with a plurality of bristles and a spacer apparatus positioned to space apart the plurality of bristles to provide at least one reservoir within the plurality of bristles. The spacer apparatus defines at least one opening extending through the spacer apparatus that allows fluid passage therethrough to the at least one reservoir to assist in removal of paint from the plurality of bristles when fluid is provided therein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of pending U.S. application Ser. No.14/232,752, filed 14 Jan. 2014, (now U.S. Pat. No. ______) which is the§371 U.S. National Stage of International Application No.PCT/US2012/043728, filed 12 Jun. 2012, which claims the benefit of U.S.Provisional Application Ser. No. 61/509,048 filed 18 Jul. 2011, entitled“PAINT BRUSH AND METHOD REGARDING SAME,” each of which is incorporatedherein by reference in its entirety.

BACKGROUND

The present disclosure herein relates generally to paint brushes. Moreparticularly, the disclosure herein pertains to paint brushes that areeasier to clean.

Paint brushes may be cleaned in various ways. For example, brushes maybe cleaned using water or solvent. In the case of latex paints, forexample, brushes may be held in various positions under running water inan attempt to remove paint from the bristles.

Many paint brush configurations use one or more spacers to create areservoir in the middle of bristles to hold paint such that the paintbrush can effectively be used (e.g., paint is held in the reservoir whenpaint is applied to the bristles by a user and prior to the applicationof the paint to an object). Without an adequate reservoir, such brushesare generally not as effective.

However, often when a brush is cleaned, paint existing deep in bristles(e.g., such as in and around the reservoir) may not be completelyremoved. As such, the paint may later dry and harden, thus stiffen andreduce the flexibility of the brush making it undesirable for use in thefuture.

Various techniques have been described to address the problems withcleaning brushes. However, such techniques are inadequate for variousreasons. For example, one or more of such techniques involve provisionof an inadequate reservoir in the paint brush leading to ineffectivepainting and/or involve complex structure that increases the cost ofsuch paint brushes.

SUMMARY

The disclosure herein relates generally to paint brushes and methods formaking the same. Generally, the disclosure herein pertains to the use ofa spacer (e.g., which defines an opening therethrough) that creates atleast one reservoir in a plurality of bristles of a paint brush. Theopening in the spacer is used as a fluid passageway to the at least onereservoir to assist in removal of paint from the plurality of bristles.

One exemplary embodiment of a paint brush may include a brush handle(e.g., a brush handle that includes a handle portion and an attachmentportion) and a plurality of bristles extending from a distal bristle endregion to a proximal bristle end region. The attachment portion of thebrush handle defines at least one channel extending from a distal outletopening to a proximal inlet opening located closer to the handle portionthan the distal outlet opening. Further, the paint brush includes aferrule extending around and in contact with at least a portion of theplurality of bristles at the proximal bristle end region (e.g., and, inone or more embodiments also may be coupled to at least a portion of theattachment portion), and a spacer apparatus extending from a proximalend to a distal end and positioned to space apart the plurality ofbristles at the proximal bristle end region to provide at least onereservoir within the plurality of bristles (i.e., the spacer apparatusdefines at least one opening extending through the spacer apparatus fromthe proximal end to the distal end). At least a portion of the pluralityof bristles at the proximal bristle end region are coupled between theferrule and the spacer apparatus. Further, the at least one channel ofthe attachment portion and the at least one opening of the spacerapparatus define a passageway that allows fluid passage from theproximal inlet opening of the attachment portion to the at least onereservoir to assist in removal of paint from the plurality of bristleswhen fluid is provided into the proximal inlet opening of the attachmentportion.

In one or more embodiments of the paint brush, the ferrule may includeat least one inner surface in contact with the plurality of bristles,and the spacer apparatus may include one or more inner surfaces adjacentthe at least one opening and one or more outer surfaces facing the leastone inner surface of the ferrule. For example, the one or more outersurfaces of the spacer apparatus and the at least one inner surface ofthe ferrule may define a bristle region within which the plurality ofbristles are located.

Further, for example, in one or more embodiments of the paint brush, thepaint brush may include one or more of the following features: anadhesive may be provided in the bristle region to couple the pluralityof bristles at the proximal bristle end region to the ferrule and thespacer apparatus; an adhesive may seal the bristle region about theentire perimeter of the spacer apparatus between the one or more outersurfaces of the spacer apparatus and the at least one inner surface ofthe ferrule; the ferrule may extend from a distal end to a proximal endwith the proximal end of the ferrule located closer to the handleportion than the proximal end of the spacer apparatus, and the proximalend of the spacer apparatus may be located closer to the handle portionthan the proximal bristle end region; the spacer apparatus may be spacedfrom an inner surface of the ferrule by a plurality of spacing elements;the ferrule may include an inner surface in contact with the pluralityof bristles with a plurality of grooves being defined in the innersurface; the ferrule may be a seamless ferrule; the at least one openingof the spacer apparatus may be configured to restrict the ingress ofpaint from the at least one reservoir into the at least one channel; anda plug portion configured to extend into the at least one opening of thespacer apparatus to selectably close the proximal inlet opening andremove material in the at least one opening when positioned therein.

Further, in one or more embodiments, the handle portion may define avoid region proximate the proximal inlet opening to allow accessthereto. For example, the handle portion may include an elongated handlemember extending between a proximal end and a distal end and first andsecond spaced apart arm members coupling the distal end of the elongatedhandle member to first and second spaced apart portions of theattachment member (e.g., the void region being located between the firstand second spaced apart members); the handle portion may include anelongated handle member extending between a proximal end and a distalend and a solid material handle body member extending from and couplingthe distal end of the elongated handle member to and along a width ofthe attachment member (e.g., wherein the void region is located on atleast one side of the solid material handle body member); or the handleportion may include an elongated handle member extending between aproximal end and a distal end and a single curved arm member couplingthe distal end of the elongated handle member to a portion of theattachment member (e.g., wherein the void region is located between theproximal inlet opening and a portion of the single curved arm member).

An exemplary method of manufacturing a paint brush is also described.For example, the method may include: providing a plurality of bristlesextending from a distal bristle end region to a proximal bristle endregion; providing a ferrule extending from a proximal end to a distalend (e.g., wherein the ferrule defines a bristle opening); locating theplurality of bristles into the bristle opening of the ferrule; insertinga spacer apparatus within the proximal bristle end region of theplurality of bristles to space apart at least a portion of the pluralityof bristles to provide at least one reservoir within the plurality ofbristles (e.g., wherein the spacer apparatus defines a least one openingextending through the spacer apparatus from a proximal end to a distalend thereof); inserting a mandrel into the proximal end of the ferruleto configure the plurality of bristles; providing adhesive in a bristleregion defined between the spacer apparatus and the ferrule to couple atleast a portion of the plurality of bristles at the proximal bristle endregion to the spacer apparatus and the ferrule; providing a brush handle(e.g., a brush handle that includes a handle portion and an attachmentportion, wherein the attachment portion defines at least one channelextending from a distal outlet opening to a proximal inlet openinglocated closer to the handle portion than the distal outlet opening);and coupling the attachment portion of the brush handle and the ferrulesuch that the at least one channel of the attachment portion and the atleast one opening of the spacer apparatus define a passageway thatallows fluid passage from the proximal inlet opening of the attachmentportion to the at least one reservoir to assist in removal of paint fromthe bristles when fluid is provided into the proximal inlet opening.

In one or more embodiments of the method, the method may include one ormore of the following: providing adhesive in the bristle region aboutthe entire perimeter of the spacer apparatus between one or more outersurfaces of the spacer apparatus and at least one inner surface of theferrule; positioning the spacer apparatus such that the proximal end ofthe ferrule is located closer to the handle portion than the proximalend of the spacer apparatus and the proximal end of the spacer apparatusis located closer to the handle portion than the proximal bristle endregion to create a channel for receiving the adhesive between the spacerapparatus and an inner surface of the ferrule; and using a plurality ofspacing elements to space the spacer apparatus from an inner surface ofthe ferrule.

Still further, another exemplary paint brush may include a plurality ofbristles extending from a distal bristle end region to a proximalbristle end region and a ferrule extending between a proximal end and adistal end (e.g., ferrule extending around and in contact with at leasta portion of the plurality of bristles at the proximal bristle endregion). Further, the paint brush may include a spacer apparatusextending from a proximal end to a distal end and positioned to spaceapart the plurality of bristles at the proximal bristle end region toprovide at least one reservoir within the plurality of bristles (e.g.,the spacer apparatus defines at least one opening extending through thespacer apparatus from the proximal end to the distal end). At least aportion of the plurality of bristles at the proximal bristle end regionmay be coupled between the ferrule and the spacer apparatus with the atleast one opening of the spacer apparatus defining a passageway thatallows fluid passage therethrough to the at least one reservoir toassist in removal of paint from the plurality of bristles when fluid isprovided therein. Still further, a brush handle may be attachable (e.g.,a detachable brush handle) at the proximal end of the ferrule.

The above summary is not intended to describe each embodiment or everyimplementation of the present disclosure. A more complete understandingwill become apparent and appreciated by referring to the followingdetailed description and claims taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of a paintbrush.

FIG. 2 is a plan view of the paint brush of FIG. 1.

FIG. 3 is an exploded partial perspective view of the paint brush ofFIG. 1.

FIG. 4 is a transparent partial perspective view of the paint brush ofFIG. 1.

FIG. 5A is a cross section view of the paint brush of FIG. 1 taken alongline 5A-5A of FIG. 2.

FIG. 5B is a cross section view of the paint brush of FIG. 1 taken alongline 5B-5B of FIG. 2.

FIG. 5C is a cross section view of the paint brush of FIG. 1 taken alongline 5B-5B of FIG. 2 with a plug portion provided for use therewith.

FIGS. 6A-6C are perspective view of alternative paint brushes.

FIGS. 7A-7E are perspective views for illustrating one exemplaryembodiment of making a paint brush such as that shown in FIG. 1.

FIG. 8 is a flow chart illustrating one exemplary embodiment of making apaint brush such as that shown in FIG. 1.

The figures are rendered primarily for clarity and, as a result, are notnecessarily drawn to scale.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In the following detailed description of illustrative embodiments,reference is made to the accompanying figures of the drawing which forma part hereof, and in which are shown, by way of illustration, specificembodiments which may be practiced. It is to be understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from (e.g., still falling within) the scope of the disclosurepresented hereby.

Exemplary paint brushes and methods regarding such paint brushes (e.g.,methods of manufacturing or use thereof) shall generally be describedwith reference to FIGS. 1-8. It will be apparent to one skilled in theart that elements from one embodiment may be used in combination withelements of the other embodiments, and that the possible adapterapparatus embodiments using features set forth herein is not limited tothe specific embodiments described. Further, it will be recognized thatthe embodiments described herein will include many elements that are notnecessarily shown to scale. Further, it will be recognized that the sizeand shape of various elements herein may be modified without departingfrom the scope of the present disclosure, although one or more shapesand sizes may be advantageous over others.

FIG. 1 is a perspective view of a paint brush 10 extending along axis 15from a distal bristle end portion 112 (e.g., including the ends of thebristles) to a proximal handle end 114 (e.g., including a handle memberfor the user to grasp). The paint brush 10 includes a bristle portion 12extending along axis 15 coupled to a brush handle 14 that also extendsalong axis 15. It will be recognized that the bristle portion 12, brushhandle 14, and components thereof, need not be centered or symmetricalwith respect to axis 15. For example, the brush handle 14 may include anattachment portion attached to the bristle portion 12 that issymmetrical to the axis 15, but include a handle portion that is notcentered or symmetrical on the axis 15.

FIG. 2 is a plan view of the paint brush 10, FIG. 3 is an explodedpartial perspective view of the paint brush 10, FIG. 4 is a transparentpartial perspective view of the paint brush 10, and FIG. 5 (includingboth FIGS. 5A and 5B) show cross section views of the paint brush 10. Asshown in FIGS. 1-5, the bristle portion 12 coupled to the brush handle14 of the exemplary paint brush 10 includes a spacer apparatus 16, aferrule 20, and a plurality of bristles 22.

Generally, the spacer apparatus 16 creates at least one reservoir 38 inthe plurality of bristles 22 (see, e.g., FIG. 5B) of the paint brush 10.Further, generally, the spacer apparatus 16 defines an opening 18therethrough that is used as a fluid passageway to the at least onereservoir 38 to assist in removal of paint from the plurality ofbristles (e.g., for ease in cleaning the paint brush 10).

Further, generally, the plurality of bristles 22 extend from a distalbristle end region 122 to a proximal bristle end region 123 with theferrule 20 extending around and in contact with at least a portion ofthe plurality of bristles 22 at the proximal bristle end region 123. Thespacer apparatus 16 is positioned to space apart the plurality ofbristles 22 at the proximal bristle end region 123 to provide the atleast one reservoir 38 within the plurality of bristles 22. At least aportion of the plurality of bristles 22 at the proximal bristle endregion 123 are coupled (e.g., using an adhesive, such epoxy) between theferrule 20 and the spacer apparatus 18.

As shown in FIGS. 1-5, the brush handle 14 of the paint brush 10 mayinclude a handle portion 30 and an attachment portion 32. In at leastone embodiment, the attachment portion 32 of the brush handle 14 definesat least one channel 40 extending from a distal outlet opening 42 to aproximal inlet opening 44 located closer to the handle portion 30 thanthe distal outlet opening 42. In such an exemplary configuration, theferrule 20 extends around and in contact with at least a portion of theplurality of bristles 22 at the proximal bristle end region 123.Further, for example, in one or more embodiments, the ferrule may alsobe coupled to at least a portion of the attachment portion 32 or, inother embodiments, the ferrule may be provided as a part of the handle.As such, the at least one channel 40 of the attachment portion 32 andthe at least one opening 18 of the spacer apparatus 16 define apassageway that allows fluid passage from the proximal inlet opening 44of the attachment portion 32 to the at least one reservoir 38 (e.g., viathe at least one opening 18 of the spacer apparatus 16) to assist inremoval of paint from the plurality of bristles 22 when fluid isprovided into the proximal inlet opening 44 of the attachment portion32. For example, the proximal inlet opening 44 may be held under afaucet by a user causing a flow of water through the passageway to cleanthe bristles 22, the brush 10 may be dip in a bucket of water andremoved causing a flow of water through the passageway to clean thebristles 22, etc.

In one exemplary embodiment, the spacer apparatus 16 extends from aproximal end 116 to a distal end 117 along the axis 15. Further, thespacer apparatus 16 may include one or more inner surfaces 160 adjacentthe at least one opening 18 and one or more outer surfaces 162 (e.g.,facing an inner surface 170 of the ferrule 20 when assembled).

In one exemplary embodiment, the ferrule 20 extends from a proximal end126 to a distal end 127. Further, the ferrule 20 includes at least oneinner surface 170 that defines a bristle opening 21 therethrough (e.g.,for receiving the plurality of bristles 22 therein when assembled). Atleast in one embodiment, the one or more outer surfaces 162 of thespacer apparatus 16 and the at least one inner surface 170 of theferrule 20 define a bristle region 133 (see, e.g., FIG. 5A) within whichthe plurality of bristles 22 are positioned when assembled. For example,an adhesive 141 may be provided in the bristle region 133 to couple theplurality of bristles 22 at the proximal bristle end region 123 to theferrule 20 (e.g., the at least one inner surface 170 thereof) and thespacer apparatus 16 (e.g., the one or more outer surfaces 162 thereof).

The plurality of bristles 22 (e.g., any number of filaments or bristles)may be formed of any suitable material for painting and the presentdisclosure is not limited to any particular type of bristles. Forexample, such bristles 22 may be formed of synthetic filaments such asnylon or any other materials, ox ear hair, horse hair, boar's hair, etc.

The ferrule 20 (e.g., centered along axis 15) which can be grasped by auser when painting may be formed of any suitable material. For example,in one or more embodiments, the ferrule 20 may be formed of at least oneof plastic, one or more metals (e.g., stainless steel, plated aluminum,plated steel, etc.), cardboard, paper film, adhesive tape, wood, etc.).Further, the ferrule may be an extruded part, a stamped part, moldedpart, or machined part. For example, the ferrule 20 may be a seamlessferrule (e.g., formed by extrusion). Further, the ferrule 20 may beformed of one or more components with one or more seams. For example,the ferrule 20 may be a single component (e.g., stamped aluminum) formed(e.g., folded) to receive the plurality of bristles (e.g., either beforeor after insertion therein) with a seam (e.g., parallel to axis 15extending from the proximal end 126 to the distal end 127) as shown bydashed line 129 in FIG. 3, or the ferrule 20 may be formed of multiplecomponents (e.g., stamped aluminum) to receive the plurality of bristles(e.g., formed either before or after insertion therein) with one or moreseams that form a single unitary ferrule component defining the bristleopening 21 along axis 15 (e.g., two or more components clamped togetherwith the bristles in between).

The bristle opening 21 of the ferrule 20 extending along the axis 15from the proximal end 126 to the distal end 127 is elongated in adirection orthogonal to the axis 15 (which generally defines the width37 of the paint brush 10 as shown in FIG. 2, which may also be referredto herein as the maximum width of the paint brush 10). Such a paintbrush 10 may be of various sizes (e.g., 1 inch, 1.5 inches, 2 inches,2.5 inches, 3 inches, 4 inches, etc.) corresponding to the width of theferrule 20. Further, the brush, and as such, the bristle opening (orshape of the bristles or other components of the brush such as theferrule or spacer apparatus) could be of any other shape or size (e.g.,circular, such as one including bristles that extend to a tapered endfrom the circular pattern of bristles; square, such as one thatterminates in more square shaped tapered bristle ends, etc.). Thepresent disclosure is not limited to only a rectangular shaped brushconfiguration or any other shape or size described herein.

In one or more embodiments, the at least one inner surface 170 of theferrule 20 in contact with the plurality of bristles 22 when assembledincludes a plurality of grooves 167 defined therein (see, e.g., FIG.5A). Such grooves 167 may be defined with any spacing about the innersurface 170 of the ferrule 20 and in any suitable shape. For example,such grooves may be provided during an extrusion process or may beotherwise physically formed therein (e.g., material removal or formingprocesses such as etching, stamping, grinding, machining, etc.).

Such grooves 167 may provide one or more benefits in one or moreembodiments of the paint brush 10. For example, as shown in FIG. 5A,adhesive 141 in the bristle region 133 between the ferrule 20 and thespacer apparatus 16 may not be present at the distal end 127 of theferrule 20. With grooves 167 extending to the distal end 127, or withgrooves only defined at the distal end 127 in the inner surface 170,fluid may travel into such grooves 167 between the inner surface 170 ofthe ferrule 20 and the plurality of bristles 22 therein to assist incleaning the paint brush 10 from the distal side of the brush 10 (e.g.,the brush may be dipped into water or solvent with such fluid travellinginto the bristles through the grooves 167). As such, fluid may beassisted in its flow at the outside of the plurality of bristles 22adjacent the ferrule 20 as well as proximate the at least one reservoir38 defined within the bristles 22.

Further, such grooves 167 when provided at least towards the proximalend 126 of the ferrule may be used to enhance the bonding in the bristleregion 133 between the ferrule 20 and the plurality of bristles 22. Forexample, in such embodiments, the grooves may be finer grooves about theinner surface 170 or may be any surface texturing suitable to providesuch enhanced bonding to the plurality of bristles 22 adjacent theferrule 20.

The spacer apparatus 16 (e.g., centered along axis 15) which providesfor the formation of the at least one reservoir 38 to provide a qualitypaint brush 10 (e.g., a paint brush that holds in the reservoir andreleases from the reservoir a sufficient quantity of paint, whichprevents skipping or minimizes brush marks, which ensures laying downadequate layer of paint, etc.), and which also defines the at least oneopening 18 for fluid flow therethrough to the at least one reservoir 38to assist in cleaning the plurality of bristles 22, may be formed of anysuitable material. For example, in one or more embodiments, the spacerapparatus 16 may be formed of at least one of plastic, one or moremetals, wood, composite, foam, ceramic, etc. Further, the spacerapparatus may be an extruded part, a molded part, a machined part, a cutpart, etc.

In one or more embodiments, the ferrule 20 and the spacer apparatus 16(e.g., including any spacing elements therebetween) may be formed as anintegral component. For example, such a component may be formed byextrusion. Still further, the brush handle (or one or more portionsthereof, such as the attachment portion) may be formed integrally withthe ferrule (e.g., a single brush handle and ferrule component). Stillfurther, the ferrule, or parts thereof, could be formed as a part of thebrush handle and the bristles coupled in the ferrule thereof (e.g., suchas by clamping two ferrule and handle portion structures together abouta plurality of bristles). Still further, any of the spacer, ferrule,attachment portion, and even the handle portion (or portions thereof)may be integrally formed together as a single piece or may be formedseparately (e.g., the ferrule may be formed as part of the brush handle.

Further, in one or more embodiments, the spacer apparatus 16 may includeone spacer component for creating a single reservoir in the plurality ofbristles 22 or may include multiple spacer components that createmultiple reservoirs in the plurality of bristles 22. For example, asshown in FIGS. 3-5, the spacer apparatus 16 is a spacer componentextending along the axis 15 from the proximal end 116 to the distal end117 and is elongated in a direction orthogonal to the axis 15 thatcreates a single reservoir 38 in the plurality of bristles 22 proximatethe distal end 117 of the spacer apparatus 16. In such a configuration,the spacer apparatus 16 may define the opening 18 as a narrow openingfrom the proximal end 116 to the distal end 117 which is also elongatedin a direction orthogonal to the axis 15. In one or more embodiments,the narrow opening 18 defined by the spacer apparatus 16 may have alength in the direction orthogonal to the axis 15 that is at least 30percent, 40 percent, 50 percent, or 60 percent of the maximum width ofthe paint brush. One will recognize that due to structural limitationsin smaller brushes (e.g., a one inch brush), that such a percentage ofchannel length versus brush width may be at the lower end. However, forlarger width brushes, it may be advantageous that the narrow opening 18be at least 50 percent of the maximum width of the brush 10 to create awider fluid opening into the bristles 22 along a substantial portion ofthe width of the brush 10.

Similarly, for example, a paint brush may include multiple spacercomponents (e.g., similar to that shown in FIGS. 3-5) that createmultiple reservoirs in the plurality of bristles 22. Such spacercomponents may be stacked along the thickness of the brush (e.g.,parallel to the narrow opening 18) and separated by at least a portionof the bristles 22, and/or, for example, such spacer components may bepositioned side by side within the bristles to create multiplereservoirs. Any configuration of multiple spacer components that createmultiple reservoirs (e.g., separated by bristles) may be used (e.g.,such as in larger size brushes). Further, one or more of such multiplespacer components may include an opening extending therethrough forproviding the enhanced cleaning functionality described herein.

Further, in one or more embodiments, the spacer apparatus 16 may beformed of one or more components (e.g., along the axis 15). For example,as will be described herein with respect to one or more manufacturingmethods for the paint brush 10, such components of the spacer apparatus16 may include a primary spacer component 52 and an extension component54. For example, primary spacer component 52 may be used to spread orspace apart the plurality of bristles 22 to form the at least onereservoir 38 and an extension component 54 may be used to extend theprimary spacer 52 such that the proximal end 116 is adjacent to, orcoupled with the brush handle 14 (e.g., lies along axis 15 within the atleast one channel 40 defined in the brush handle 14).

Further, for example, in one or more embodiments, the spacer apparatus16 may be configured to restrict paint in the at least one reservoirfrom breaching (e.g., flow past) the proximal end 116 of the spacerapparatus 16 (e.g., when a user is painting a ceiling and holding thebrush with bristles upward). For example, the spacer apparatus 16 or theat least one opening 18 defined therethrough may be configured torestrict the flow of paint within the at least one opening 18 and/orkeep the paint from breaching or flowing past the proximal end 116 ofthe spacer apparatus 16. For example, in one or more embodiments, theopening 18 may be defined as a narrow opening having a gap dimensionthat prevents paint (e.g., due to the paint's viscosity) from enteringthe narrow opening or at least prevents the flow of paint from exitingthe opening at the proximal end 116 of the spacer apparatus. Further,for example, a plurality of openings may be formed through the spacerapparatus (e.g., a structure defining small openings, such as ahoneycomb structure or a mesh or screen structure, lying orthogonal toaxis 15) that prevents the flow of paint from exiting the opening at theproximal end 116 of the spacer apparatus. Further, for example, in oneor more embodiments, the spacer apparatus 16 may be configured with aone way valve (e.g., a duck bill valve, a flap, etc.) extending from orprovided within the apparatus to prevent paint from entering the opening18 or at least prevents the flow of paint from exiting the opening atthe proximal end 116 of the spacer apparatus 16.

In one or more embodiments, the opening 18 at the distal end 117 of thespacer apparatus 16 may be configured to function as part of the atleast one reservoir 38 but still prevent the flow of paint from exitingthe opening at the proximal end 116 of the spacer apparatus 16. As such,the opening 18 may add additional reservoir space to provide more paintholding capacity for a user of the paint brush 10 which may provideadditional quality benefits. For example, restriction structure may belocated more proximally in the opening 18 of the spacer apparatus 16 toprovide for such additional reservoir capacity, the opening 18 may be ofa larger dimension at the distal end 117 versus the proximal end 116 toprovide a receiving capacity for paint.

Still further, in one or more embodiments, the spacer apparatus 16 maybe spaced from the inner surface 170 of the ferrule 20 by a plurality ofspacing elements such as fins 57 or any other structure that provides aspacing function (e.g., a structure that allows bristles to be locatedin the bristle region). For example, such spacing elements (e.g., pins,fins, radially extending elements, etc.) may extend radially between theouter surface 162 of the spacer apparatus 16 and the inner surface 170of the ferrule 20. The spacing elements (such as fins 57) may be formedas part of the spacer apparatus 16, may be formed as part of the ferrule20, or may be a separate component or one or more components formedand/or used for such spacing purposes. The spacing elements assist inmaintaining dimensions of the bristle region 133 and/or the spacing ofthe bristles 22 when the paint brush 10 is being assembled (e.g., thespacing elements may also mate with openings or grooves 167). Further,for example, the spacing of such spacing elements (e.g., fins 57) aboutthe perimeter of the spacing apparatus 16 may vary and any suitablespacing size and shape may be used. In at least one embodiment, fins 57are positioned symmetrically about the axis 15 and extending radiallyfrom the outer surface 162 of the spacer apparatus 16 as shown in FIGS.3-5 (e.g., two opposing fins at the ends of the elongated spacerapparatus 16 and two opposing fins at the mid-point of the elongatedspacer apparatus 16). Further, in at least one embodiment, the spacingelements 57 may be provided as a single spacing element extendingradially along a plane orthogonal to axis 15 between the outer surface162 of the spacing apparatus 16 and the inner surface 170 of the ferrule20.

Further, in one or more embodiments, the one or more outer surfaces 162of the spacer apparatus 16 may be configured to enhance the bonding inthe bristle region 133 between the spacing apparatus 16 and theplurality of bristles 22. For example, in such embodiments, the outersurface 162 may be grooved or include any surface texturing suitable toprovide such enhanced bonding to the plurality of bristles 22 adjacentthe spacer apparatus 16.

As shown in FIGS. 5A-5B, adhesive 141 is used to couple (e.g., attach,connect, fix) the plurality of bristles 22 in the bristle region 133between the one or more outer surfaces 162 of the spacer apparatus 16and the at least one inner surface 170 of the ferrule 20. However, thebristles may be coupled in the bristle region by mechanical forcebetween the ferrule 20 and the spacer apparatus 16 (e.g., by a clampingforce). Further, for example, the adhesive 141 may be any curableadhesive (e.g., heat curable, chemically cured, etc.) suitable toaccomplish such coupling. For example, the adhesive 141 may be an epoxy.Further, for example, in at least one embodiment, the adhesive 141 issufficiently flowable to provide self-leveling when provided within achannel 147 created in the bristle region 133 by the spacer apparatus 16and ferrule 20. Further, for example, in one or more embodiments, theadhesive 141 is non-reactive with paints and/or one or more cleaningfluids (e.g., water, solvents, etc.).

In one or more embodiments, the adhesive 141 may seal the bristle region133 about the entire perimeter of the spacer apparatus 16 as shown inFIG. 5A between the one or more outer surfaces 162 of the spacerapparatus 16 and the at least one inner surface 170 of the ferrule 20.In such a manner, any fluid provided in the opening 18 at the proximalend of the spacer apparatus 16 can only flow through the opening 18 asthe region about the perimeter is entirely sealed.

Still further, for example, in one or more embodiments as shown in FIG.5B, the proximal end 126 of the ferrule 20 is located closer to thehandle portion 30 of the brush handle 14 than the proximal end 116 ofthe spacer apparatus 16, and the proximal end 116 of the spacerapparatus 16 may be located closer to the handle portion 30 than theproximal bristle end region 123 of the plurality of bristles 22. In sucha configuration, a channel 147 is created into which adhesive 141 may beprovided and in which the adhesive 141 may flow to couple the pluralityof bristles 22 at the proximal bristle end region 123 to the ferrule 20and spacer apparatus 16. Further, in at least one embodiment, theproximal end 126 of the ferrule 20 need not be located closer to thehandle portion 30 of the brush handle 14 than the proximal end 116 ofthe spacer apparatus 16, but need only be located closer to the handleportion 30 than the proximal bristle end region 123 for formation of thechannel 147.

Still further, in at least one embodiment, the length of the spacerapparatus 16 along the axis 15 from the proximal end 116 to the distalend 117 may be such that the proximal end 117 thereof mates within achannel 40 formed in the brush handle 14. In such a configuration, theproximal end 116 of the spacer apparatus 16 may be located closer to thehandle portion 30 of the brush handle 14 than the proximal end 126 ofthe ferrule 20, or they may extend the same distance, or the proximalend 126 of the ferrule 20 may be located closer to the handle portion 30of the brush handle 14 than the proximal end 116 of the spacer apparatus16 and still provide mating with the channel 40 (e.g., depending on theconfiguration of the structure defining the channel 40).

As shown in FIGS. 1-4, the brush handle 14 extends along axis 15 from adistal end portion 191 (e.g., including the attachment portion 32) to amore proximal end portion 193 (e.g., including the handle portion 30).The attachment portion 32 of the brush handle 14 may be configured inany manner suitable for coupling to the ferrule 20 (or any other portionof the bristle portion 12). For example, as shown in FIGS. 1-4, theattachment portion 32 includes an outer surface 45 extending along theaxis 15 about the perimeter thereof that mates with the inner surface170 of the ferrule 20. Such surfaces may be coupled in any manner, suchas with adhesive, mechanical fastening including interference fits,fasteners (e.g., screws, rivets, nails, etc.), etc.

As described herein, the attachment portion 32 of the brush handle 14may define at least one channel 40 extending from the distal outletopening 42 to the proximal inlet opening 44 located closer to the handleportion 30 than the distal outlet opening 42. In one embodiment as shownin FIGS. 3-4, the distal outlet opening 42 is provided such that itmates with the spacer apparatus 16 (e.g., the proximal end 116 of spacerapparatus 16 fits within the at least one channel 40 and/or is sealedtherein) to provide the passageway that allows fluid passage from theproximal inlet opening 44 of the attachment portion 32 to the at leastone reservoir 38 (e.g., via the at least one opening 18 of the spacerapparatus 16) to assist in removal of paint from the plurality ofbristles 22 when fluid is provided into the proximal inlet opening 44 ofthe attachment portion 32.

The attachment portion 32 (e.g., centered along axis 15 as shown inFIGS. 1-4) defines the at least one channel 40 for fluid flowtherethrough to the at least one reservoir 38 to assist in cleaning theplurality of bristles 22. The attachment portion 32 may be formed of anysuitable material. For example, in one or more embodiments, theattachment portion, as well as the handle portion 30, may be formed ofat least one of plastic, one or more metals, wood, composites, cork,engineered materials (e.g., material formed from recycled materialformed with adhesive), etc. Further, the attachment portion 32, as wellas the handle portion 30, may be an extruded part, a molded part, amachined part, a cut part, a part formed by one or more wood fabricationtechniques, etc.

In one or more embodiments, the attachment portion 32 and the handleportion 30 may be formed as an integral single component. In one or moreother embodiments, the attachment portion 32 and the handle portion 30may be formed of multiple components coupled together by any suitablemeans (e.g., adhesives, mechanical fasteners, etc.).

Further, in one or more embodiments, the attachment portion 32 maydefine more than one channel for receiving fluid to assist in cleaningthe paint brush 10. For example, the attachment portion 32 may beconfigured to create multiple channels that feed into the at least oneopening 18 of spacer apparatus 16, may be configured to create multiplechannels that feed into multiple openings of the spacing apparatus 16,etc.

Any configuration of such channels may be used. For example, a channelfrom one side of a brush may be used in addition to a channel from adifferent side of the brush (e.g., both may flow into the same openingdefined by the spacer apparatus 16 or different openings). Further, forexample, multiple channels may be created side by side and/or inparallel to one another, or in any other suitable manner to provide flowof fluid for assisting in cleaning the bristles of the paint brush.

Further, for example, as shown in the exemplary embodiment of FIGS. 3-5,the attachment portion 32 extends along the axis 15 from the distaloutlet opening 42 to the proximal inlet opening 44 and is elongated in adirection orthogonal to the axis 15. In such a configuration, theattachment portion 32 may define the channel 18 as a narrow channel thatextends along the axis 15 from the distal outlet opening 42 to theproximal inlet opening 44 which is also elongated in a directionorthogonal to the axis 15. In one or more embodiments, the narrowchannel 40 (like the narrow opening 18) defined by the attachmentportion 32 may have a length in the direction orthogonal to the axis 15that is at least 30 percent, 40 percent, 50 percent, or 60 percent ofthe maximum width of the paint brush. One will recognize that due tostructural limitations in smaller brushes (e.g., a one inch brush), thatsuch a percentage of channel length versus brush width may be at thelower end. However, for larger width brushes, it may be advantageousthat the narrow channel 40 be at least 50 percent of the maximum widthof the brush 10 to create a wider fluid opening into the bristles 22along a substantial portion of the width of the brush 10.

Further, in one or more embodiments, the attachment portion 32 may beconfigured to restrict paint from breaching (e.g., flow past) theproximal inlet opening 44 of the attachment portion 32. For example, theattachment portion 32 or the at least one channel 40 definedtherethrough may be configured to restrict the flow of paint within theat least at least one channel 40 and/or keep the paint from breaching orflowing past the proximal inlet opening 44 (e.g., such as when the brushis held with the bristles being upward). For example, in one or moreembodiments, the channel 40 may be defined as a narrow channel having agap dimension that prevents paint from entering the narrow channel or atleast prevents the flow of paint from exiting the channel at theproximal inlet opening 44. Further, for example, a plurality of openingsmay be formed through the attachment portion 32 (e.g., a structuredefining small openings, such as a honeycomb structure or a mesh orscreen structure, lying orthogonal to axis 15) that prevents the flow ofpaint from exiting the proximal inlet opening. Further, for example, inone or more embodiments, the attachment portion 32 may be configuredwith a one way valve (e.g., a duck bill valve, flap, etc.) extendingfrom or provided within the attachment portion 32 to prevent paint fromentering the channel 40 or at least prevent the flow of paint fromexiting the opening at the proximal inlet opening 44.

In one or more embodiments, a plug portion 175 (shown in FIG. 5C butusable with any brush embodiment described herein) may be configured toselectably close the proximal inlet opening 44 to prevent the flow ofpaint from exiting the opening at the proximal inlet opening 44. Forexample, in one embodiment, the plug portion 175 may be formed to beinserted not only within the channel 40 defined through of theattachment portion 32 but also to be inserted in the at least oneopening 18 of the spacer apparatus 16 as shown in FIG. 5C. In such amanner, the insertion into the opening 18 may remove material in the atleast one opening 18 (e.g., paint, wet or dry, that may be residingtherein). For example, the plug portion 175 may be sized relative toinner surface 160 of the spacer apparatus 16 such that it pushes any drypaint along the inner surface 160 of the spacer apparatus 16 and intothe at least one reservoir such that it can be washed away duringcleaning. Further, in one or more embodiments, the plug portion 175 neednot extend into the channel 18 and may not even extend into the channel40 of the attachment portion 32. For example, the plug portion may takethe form of a tape plug just covering the proximal inlet opening 44 andremovable when cleaning of the brush is desired, the plug portion may bedissolvable (e.g., dissolve when water is provided on the plug such thatit need not be pulled from the opening 44), etc.

Further, in one or more embodiments, the handle portion 30 may define avoid region 90 proximate the proximal inlet opening 44 to allow accessthereto such that fluid may be provided into the passageway forassisting in cleaning the bristles 22 of the paint brush 10. The voidregion 90 may be created by any one or more configurations of the handleportion 30 and connection thereof to the attachment portion 32, and thepresent disclosure is not limited to those shown or described herein.For example, various alternate handle portions are shown and describedherein with reference to FIGS. 1 and FIGS. 6A-6C.

For example, FIGS. 1 and 6A show a similar handle portion. The primarydifference between the paint brush 10 of FIG. 1 and the brush 210 shownin FIG. 6A is that the handle portion 30 of paint brush 10 includes anintegral hanging opening 183 defined therein while the handle portion230 of FIG. 6A includes a multiple component handle portion, wherein ahanging opening 283 is defined by the coupling of the components.

As such, the handle portion 230 of paint brush 210 shall be described infurther detail, but such components are similar to those of paint brush10. For example, the handle portion 230 includes an elongated handlemember 238 extending between a proximal end 234 (e.g., proximate thehanging opening 283) and a distal end 236. The handle portion 230further includes first and second spaced apart arm members 241-242coupling the distal end 236 of the elongated handle member 238 to firstand second spaced apart portions 245-246 of the attachment member 232.The void region 290 for access to the proximal inlet opening 244 definedin the attachment portion 232 is located between the first and secondspaced apart members 214, 242. As such, fluid may be easily provided tothe proximal inlet opening 244. As shown in FIGS. 1 and 6A, this createsa “Y” type handle configuration. One will also note that the arm members241-241 are somewhat thicker than the arm members of the handle portion30.

In another embodiment, as shown in FIG. 6B, the handle portion may beconfigured in a more solid configuration (e.g., without an openingcompletely through the handle proximate proximal inlet opening 344). Forexample, the handle portion 330 of paint brush 310 may include anelongated handle member 338 extending between a proximal end 334 and adistal end 336. A solid material handle body member 368 extends from andcouples the distal end 336 of the elongated handle member 338 to andalong a width of the attachment member 332. In this configuration, avoid region 340 is located on one side of the solid material handle bodymember 368. In an alternate configuration, another proximal inletopening may be provided on the other side of the paint brush 310 withanother void region created to provide flow of fluid thereto forcleaning purposes. In other words, the alternate embodiment may includeanother side opposite that shown in FIG. 6B and which is a mirror imagethereof.

In another embodiment, as shown in FIG. 6C, the handle portion may beconfigured in a lazy “S” configuration. For example, the handle portion430 of paint brush 410 may include an elongated handle member 438extending between a proximal end 434 and a distal end 436. A singlecurved arm member 439 couples the distal end 436 of the elongated handlemember 432 to a portion 468 of the attachment member 432. A void region440 is located between the proximal inlet opening 444 and a portion ofthe single curved arm member 439.

In one or more embodiments, the brush handle 14 is an attachable brushhandle that may be removed from the bristle portion 12 such that thebristle portion 12 may be cleaned separately (e.g., fluid may beprovided into the bristle portion 12). In such a configuration, theattachment portion 32 may not be provided with a channel 40 definedtherethrough as fluid may be provided directly into the at least oneopening 18 of the spacer apparatus 16 when the bristle portion 12 isremoved from the brush handle 14.

For example, in one or more embodiments, the brush handle 14 may beremovably coupled to or detachable from the bristle portion 12 by aninterference fit between the outer surface 45 of the attachment portion32 and the inner surface 170 of the ferrule 20 (e.g., the ferrule may bea rubber ferrule that is tightly secured to the outer surface 45, butremovable therefrom by a pulling action). Further, for example, in oneor more embodiments, additional structure may be used to lock and unlockthe bristle portion 12 to the brush handle 14. For example, releasableclaws (e.g., latchable mechanism) may be used to retain the bristleportion 12 on the brush handle 14, releasable fasteners may be used forsuch purposes, latches may be used, snaps may be used, removable pinsmay be used, etc.

An exemplary method of manufacturing a paint brush 10 (such as shown inFIGS. 1-5 and whose reference numbers will be used to describe such amethod) shall be described with respect to FIGS. 7A-7E, as well as theflow diagram of FIG. 8. The method 500 may include providing a pluralityof bristles 22 extending from a distal bristle end region 122 to aproximal bristle end region 123 and providing a ferrule 20 extendingfrom a proximal end 126 to a distal end 127 (e.g., wherein the ferruledefines a bristle opening 21). The plurality of bristles 22 are locatedor inserted into the bristle opening 21 of the ferrule 20 (block 501) asshown in FIG. 7A.

Further, the method 500 includes inserting (e.g., from either end of thebristles) a spacer apparatus 16 within the proximal bristle end region123 of the plurality of bristles 22 to space apart at least a portion ofthe plurality of bristles 22 to provide at least one reservoir 38 withinthe plurality of bristles 22 (block 502) as shown by the combination ofFIGS. 7A and 7B (e.g., FIG. 7A showing the spacer apparatus 16 notinserted and FIG. 7B showing the spacer apparatus inserted). In oneembodiment, only a primary spacer component 52 is inserted within theplurality of bristles 22 to provide reservoir 38 (e.g., an extensionspacer component is inserted later as described herein). However,variation of such process steps may occur depending on the componentsused. The spacer apparatus 16 (e.g., primary spacer component 52 andextension component 54) defines the opening 18 extending through thespacer apparatus 16 from the proximal end to a distal end thereof.

Still further as shown in FIG. 8, a mandrel 84 (or other shaping orprocessing device) is inserted into the proximal end 126 of the ferrule20 to configure the plurality of bristles 22 (block 503) (e.g., pack thebristles). The mandrel 84 may be of any suitable configuration foraccomplishing one or more functions. For example, as shown in FIG. 7A,the mandrel 84 includes a base 85 and a position member 86 extendingfrom the base 85 and terminating in a shaping region 87. The positionmember 86 may provide for the desired positioning of the spacerapparatus 16 within the ferrule 20 as well as the shape of the bristles22 at the distal bristle end region 122. For example, the shape ofshaping region 87 terminating the position member 84 and at theperimeter thereof configures the bristles at the proximal bristle endregion 123 such that the bristles 22 at the distal bristle end region122 have a particular shape (e.g., with the shaping region 87 as shownin FIG. 7A, the bristles 22 at the distal bristle end region 122 willhave rounded edges at the perimeter edge of the bristles). The pluralityof spacing elements 57 of the spacer apparatus 16 may be angled to matewith the shaping region 87 of the mandrel 84 to assist in packing andshaping the bristles 22. The desired positioning of the spacer apparatus16 within the ferrule 20 provides for the creation of the channel 147 asdescribed herein in which the adhesive 141 is provided (e.g., whereinthe proximal end 116 of the spacer apparatus 16 is located closer to thehandle portion 30 of the brush handle 14 than the proximal bristle endregion 123). As shown in FIG. 7C, the base 85 comes into contact withthe proximal end 126 of the ferrule 20 with the position member 86 ofthe mandrel 84 extending into the ferrule 20 to accomplish the desirableconfiguration of the bristles 22 and spacer apparatus 16.

In one embodiment of the method 500, as shown by block 504, with themandrel 84 removed (as shown in FIG. 7D which does not show the bristles22), the extension spacer component 54 may be inserted into place andcoupled to the primary spacer component 52, such as with adhesive or inany other manner (as shown in FIG. 7E which also does not show thebristles) to provide a lengthened spacer apparatus 16 along axis 15 (aswell as a lengthened opening 18 therethrough) positioned in the ferrule20. One will recognize that such components may be provided as a singlecomponent in certain configurations and the use of an extensioncomponent may not be needed in the manufacturing process, and may not bea part of a spacer apparatus in one or more brush configurations.

Further, the method 500 includes providing adhesive 141 in a bristleregion 133 defined between the spacer apparatus 16 and the ferrule 20 tocouple at least a portion of the plurality of bristles 22 at theproximal bristle end region 123 to the spacer apparatus 16 and theferrule 20 (block 505). For example, in at least one embodiment, asshown in FIG. 5B, the adhesive 141 is provided in the channel 147described herein created between the spacer apparatus 16 and the ferrule20 and the adhesive 141 is sufficiently flowable to provideself-leveling therein (e.g., the adhesive may be provided in the channelin any manner, such as with use of a nozzle). Further, for example, inone embodiment, the adhesive 141 may be provided in the bristle region133 about the entire perimeter of the spacer apparatus 16 between one ormore outer surfaces 162 of the spacer apparatus 16 and at least oneinner surface 170 of the ferrule 20. It will be recognized that theentire spacer apparatus 16 is not embedded in the adhesive 141 as theproximal end 116 thereof must be open to allow fluid to flow therein. Inother words, at least a portion of the proximal end 116 of the spacerapparatus 16 used to create the at least one reservoir 38 in thebristles is free of adhesive.

Thereafter, a brush handle is provided and coupled to the ferrule 20 ofbristle portion 12 (block 506). For example, the brush handle 14 mayinclude a handle portion 30 and an attachment portion 32, wherein theattachment portion 32 defines at least one channel 40 extending from adistal outlet opening 42 to a proximal inlet opening 44 located closerto the handle portion than the distal outlet opening. The attachmentportion 32 of the brush handle 14 may be coupled to the ferrule 20 suchthat the at least one channel 40 of the attachment portion 32 and the atleast one opening 18 of the spacer apparatus 16 define a passageway thatallows fluid passage from the proximal inlet opening 44 of theattachment portion 32 to the at least one reservoir 38 to assist inremoval of paint from the bristles 22 when fluid is provided into theproximal inlet opening 44. Still further, the brush handle may be aremovable handle (e.g., without a channel 40 being defined therein) suchas, for example, in a configuration where the bristle portion 12 isremovable from the brush handle 14 for cleaning purposes.

Illustrative embodiments of this invention are discussed and referencehas been made to possible variations within the scope of this invention.These and other variations, combinations, and modifications in theinvention will be apparent to those skilled in the art without departingfrom the scope of the invention, and it should be understood that thisinvention is not limited to the illustrative embodiments set forthherein. Accordingly, the invention is to be limited only by the claimsprovided below and equivalents thereof.

What is claimed is: 1-19. (canceled)
 20. A paint brush comprising: a brush handle comprising a handle portion and an attachment portion, wherein the attachment portion defines at least one channel extending from a distal outlet opening to a proximal inlet opening located closer to the handle portion than the distal outlet opening; a plurality of bristles extending from a distal bristle end region to a proximal bristle end region; a ferrule extending around and in contact with at least a portion of the plurality of bristles at the proximal bristle end region; and a spacer apparatus extending from a proximal end to a distal end and positioned to space apart the plurality of bristles at the proximal bristle end region to provide at least one reservoir within the plurality of bristles, wherein the spacer apparatus defines a plurality of openings extending through the spacer apparatus from the proximal end to the distal end, wherein at least a portion of the plurality of bristles at the proximal bristle end region are coupled between the ferrule and the spacer apparatus, and further wherein the spacer apparatus is configured to restrict paint in the at least one reservoir from flowing past the proximal end of the spacer apparatus.
 21. The paint brush of claim 1, wherein the plurality of openings comprises one or more structures defining small openings.
 22. The paint brush of claim 2, wherein the one or more structures are selected from a honeycomb structure, a mesh, a screen, or a combination thereof.
 23. The paint brush of claim 1, wherein the spacer apparatus is configured with a valve within the apparatus to prevent the flow of paint from exiting one or more of the plurality of openings at the proximal end of the spacer apparatus.
 24. The paint brush of claim 1, wherein the spacer apparatus is configured with a valve extending from the apparatus to prevent the flow of paint from exiting one or more of the plurality of openings at the proximal end of the spacer apparatus.
 25. The paint brush of claim 4, wherein the valve is a one-way valve.
 26. The paint brush of claim 5, wherein the valve is a one-way valve.
 27. The paint brush of claim 6, wherein the one-way valve is a duck bill valve or a flap.
 28. The paint brush of claim 7, wherein the one-way valve is a duck bill valve or a flap.
 29. The paint brush of claim 1, wherein one or more of the plurality of openings are configured to function as part of the at least one reservoir.
 30. The paint brush of claim 1, wherein one or more of the plurality of openings includes a restriction structure located proximally in the opening.
 31. The paint brush of claim 1, wherein one or more the plurality of openings is configured to be larger at the distal end relative to the proximal end. 